Repair Instructions

Repair instructions
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points, are summarized here.

Transmission
When an automatic transmission is exchanged, the VW ATF in the planetary gearbox, and the gear oil in the final drive, is to be checked and topped up as necessary.





- For transmission repairs, an exchange component is available for the shift elements, which is often more cost effective.
- When installing a transmission, ensure that the dowel sleeves are installed correctly.

Gaskets, oil seals





- Radial shaft seals: Pack space between sealing lips with grease before installing.
- Always install new O-rings.
- After installing, check ATF level in planetary gearbox or gear oil in final drive, adjust to correct level if necessary.

Locking elements
- Do not overstretch circlips; replace if necessary.
- Circlips must be properly seated in the grooves.





- Replace spring pins. Installation position: Slot longitudinal to line of force.

Shims
- Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
- Check for signs of burr and damage. Install only shims which are in perfect condition.

Bearings
- Tapered roller bearings are allocated in the parts catalog according to transmission build date and code letters.
- Always replace tapered roller bearings, which are mounted on a shaft together and use bearings from a single manufacturer.
- Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.
- Heat the inner races of tapered roller bearings to approx. 100°C before inserting.
- Do not interchange the inner and outer races of same size bearings.

Nuts, bolts





- Nuts and bolts for attaching covers and housings must be loosened and tightened crosswise.
- Do not distort particularly sensitive parts, e.g. valve body, and loosen or tighten diagonally in stages.
- The tightening torques stated apply to unoiled nuts and bolts.
- Threads of bolts that are secured by locking fluid are to be cleaned with a wire brush. Insert bolts with AMV 185 100 A1.
- Always replace self-locking nuts.

Inner plates





- Place new inner plates in ATF fluid for 15 minutes before installing.

Valve body
- Replace the valve body if any of the selector elements are scorched.

Clutches
- Clutches K1, K2 and K3 should be dismantled only for cleaning. If parts are faulty, replace clutch. Allocate clutches according to transmission code letters.

On Board Diagnostic (OBD)





- Before repair work is carried out on the automatic transmission, the cause of the malfunction should be determined as precisely as possible with the aid of On Board Diagnostic (OBD).